Prefabricated wall apparatus and method

ABSTRACT

A prefabricated wall module may include framing members and one or more insulations members. The insulation member may have pre-incisions, as made by a hot-wire, defining service fitting accommodations. The service fitting accommodations are accessible on the inside face of the insulation. The service fitting accommodations may be either or both of vertically or laterally extending, and are located in the same places in each module, the vertical locations being next to the studs, to which service fittings may typically be mounted, the lateral accommodations being at heights typical of switches and wall outlets. The insulation members may be supplied with tabs filling the accommodations. The tabs may be snapped out as required. The insulation members may have stud channels that are shallower than the studs, such that an air gap is established between the insulation and the internal gypsum board covering.

This application is a continuation of U.S. patent application Ser. No.14/021,683 filed Sep. 9, 2013, the specification and drawings thereofbeing incorporated in their entirety herein by reference.

FIELD OF INVENTION

This description relates to an insulated wall construction apparatus andmethod.

BACKGROUND OF THE INVENTION

A modular wall panel typically includes a combination of framingelements and insulation. It may also include inside sheathing, typicallygypsum wall board of some kind, and external or outside sheathing whichmay be plywood or oriented strand board. Modular insulated walls areaddressed in U.S. Pat. No. 4,628,650 of Parker, for example.

SUMMARY OF INVENTION

The following summary may introduce the reader to the more detaileddiscussion to follow. The summary is not intended to, and does not,limit or define the claims. In an aspect of the invention there is aninsulation monolith with snap-out service accommodation access. In afeature of that aspect, the service accommodation is accessible fromfront face of the unit, i.e., the face facing inwardly toward the roomof which the module forms a portion of the wall. In another aspect ofthe invention, there is a method of making any aspect of feature ofapparatus shown or described herein.

In another aspect of the invention there is an insulation monolith withan end stud accommodation, the end stud accommodation being ofselectable width between at least a first width and a second widthgreater than the first width.

In another aspect of the invention there is an insulation monolith thatdefines a wall framing jig, that aspect including the method of usingthe jig to construct a wall module thereon, whereby the wall module maybe said to be self-jigging.

In another aspect of the invention there is an insulation member for usein construction of a modular wall structure including wall studs,wherein the insulation member includes at least one stud accommodation,and the stud has a width that is greater than the depth of the studaccommodation.

In another aspect of the invention, there is an insulation member foruse in construction of a modular wall structure including wall studs,where the insulation member defines a plug conforming to a bay or cavitydefined between a pair of adjacent studs, wherein the plug is shallowerthan the cavity. In a feature of that aspect of the invention, theinsulation member also has an abutment, or indexing element that seatsoutside the studs, while the plug extends inwardly from the indexingmember into the cavity. In another feature, the insulation memberincludes at least one stud channel, and, when a first stud is installedtherein it stands proud of the plug in the inside direction relative tothe wall.

In an aspect of the invention there is an insulation member for apre-fabricated wall construction. It has a body having a height, a widthand a depth. The body has at least a first stud accommodation and asecond stud accommodation defined therein. The first and second studaccommodations are spaced width-wise apart from each other, and runheighth-wise. The body has an outside face and an inside face. The firstand second stud accommodations are shallower than the depth of the body,and open toward the inside face. The body has at least a first serviceaccommodation defined therein, the first service accommodation beingadjacent to the first stud accommodation, and being located between thefirst and second stud accommodations. The first service accommodationhas access from the inside face.

In a feature of that aspect of the invention, the body includes anaccommodation for at least one of (a) a head plate; and (b) a footplate. In another feature, the first service accommodation runsheighth-wise along the first stud accommodation. In another feature, asecond service accommodation is located adjacent to the second studaccommodation. In a further feature, the first service accommodationruns heighth-wise along the first stud accommodation, and the secondservice accommodation runs heighth-wise along the second studaccommodation. In still another feature, the first service accommodationextends width-wise between the first and second stud accommodations. Inan additional feature a second service accommodation extends width-wisebetween the first and second stud accommodations. In another feature,the first service accommodation is shallower than the first studaccommodation. In another feature, the first service accommodation is atleast ¾ inches deep.

In another feature there is a combination of the insulated member and afirst insulation blank, the first insulation blank conforming to thefirst service accommodation; and the first insulation blank beingmovable to govern access to the first service accommodation.

In another aspect of the invention there is a pre-fabricated insulationmember having a body portion for installation between first and secondwall studs, the insulation member having a height, a width, and athrough-thickness, the through-thickness being smaller than either ofthe height and the width. The insulation member body portion has a firstface, the first face extending heighth-wise and width-wise. The bodyportion has a first service accommodation pre-defined therein. Theservice accommodation is accessible from the first face.

In a feature of that aspect, the insulation member has a first studinterface and the first service accommodation runs adjacent to the firststud interface. In another feature, the member has a first studinterface and a second stud interface, and the first serviceaccommodation runs width-wise across the body portion between the firstand second stud interfaces. In a further feature, the member has a firststud interface and a second stud interface, the first serviceaccommodation runs along the first stud interface, and the insulationmember has a second service accommodation running along the second studinterface; the second service accommodation being accessible from thefirst face. In a still further feature, the body member has a first studinterface and a second stud interface. The prefabricated insulationmember also includes a second service accommodation. The first serviceaccommodation runs predominantly heighth-wise along the first studinterface. The second service accommodation runs width-wise between thefirst stud interface and the second stud interface. In an additionalfeature, the body member has a third service accommodation. The thirdservice accommodation running along the second stud interface; and thethird service accommodation being accessible from the first face.

In still another feature, the pre-fabricated insulation member includesa second member; the second member fitting within the first serviceaccommodation; and the second member being removable from the firstservice accommodation. In another feature, a frangible blank occupiesthe first service accommodation. In a further feature, the body memberand the frangible blank are parts of a single insulation monolith. Inanother further feature, the first service accommodation is shallowerthan the through-thickness of the body member.

In another aspect of the invention, there is a combination of aninsulation member for a pre-fabricated wall construction and framingmembers of the pre-fabricated wall construction. The framing membersinclude at least first and second spaced-apart studs and a cavity formedtherebetween. The wall construction has a height, a width, and athrough-thickness. The framing members include at least first and secondspaced-apart studs, the studs having a thickness and a width, and acavity formed between the first and second studs. The cavity has a depthin the through-thickness direction of the wall-construction. Theinsulation member defines a plug for the cavity, and the plug is shorterin the through-thickness direction than the depth of the cavity.

In a feature of that aspect of the invention, the insulation member hasrespective first and second stud interface fittings defining respectiveaccommodations for the first and second studs, and the respectiveaccommodations are each less deep in the through-thickness direction ofthe wall construction than the width of the first and second studs inthe through-thickness direction of the wall construction. In anotherfeature, the wall construction has an inside and an outside, the studsstand proud of the plug toward the inside of the wall construction, andthe plug has at least a first service fitting accommodation definedtherein, the first service fitting accommodation being accessible fromthe inside of the wall construction. In a further feature, the firstservice fitting accommodation is filled with a blank. In an additionalfeature, the blank is frangibly removable from the accommodation. Inanother feature, the combination includes at least three studs and atleast two adjacent cavities defined to either side of one of the atleast three studs; the first stud seats in a stud channel defined in theinsulated member, and the first service fitting accommodation runs alongthe first stud adjacent to the stud channel. In another feature thefirst and second stud accommodations are formed on one of (a) 12″centers; (b) 16″ centers; (c) 19½″ centers; (d) 24″ centers.

BRIEF DESCRIPTION OF THE ILLUSTRATIONS

These and other features and aspects of the invention may be explainedand understood with the aid of the accompanying illustrations, in which:

FIG. 1a is a perspective view of a pre-fabricated insulation memberaccording to an aspect of the invention herein;

FIG. 1b is a sectional view on section ‘1 b-1 b’ of FIG. 1a , withcross-hatching omitted for clarity;

FIG. 1c is the sectional view of FIG. 1b with two heighth-wise extendingfrangible members removed;

FIG. 1d is a partial sectional view of section ‘1 d-1 d’ of FIG. 1a ,with cross-hatching omitted for clarity;

FIG. 1e is the sectional view of FIG. 1d with a width-wise extendingfrangible member removed;

FIG. 2a is a perspective view of an alternate embodiment ofpre-fabricated insulation member to that of FIG. 1 a;

FIG. 2b is a sectional view on section ‘2 b-2 b’ of FIG. 2a , withcross-hatching omitted for clarity;

FIG. 2c is the sectional view of FIG. 2b with two heighth-wise extendingfrangible members removed;

FIG. 2d is a partial sectional view of section ‘2 d-2 d’ of FIG. 2a ,with cross-hatching omitted for clarity;

FIG. 2e is the sectional view of FIG. 2d with a width-wise extendingfrangible member removed;

FIG. 3a is a perspective view of a further alternate embodiment ofpre-fabricated insulation member to that of FIG. 1 a;

FIG. 3b is a corner sectional detail taken on section ‘3 b-3 b’ of thepre-fabricated insulation member of FIG. 3 a;

FIG. 4a is a perspective view of a further alternate embodiment ofpre-fabricated insulation member to that of FIG. 1 a;

FIG. 4b is a corner sectional detail taken on section ‘4 b-4 b’ of thepre-fabricated insulation member of FIG. 4 a;

FIG. 5a shows a billet of insulation material for making a furtherembodiment of pre-fabricated insulation member different from that ofFIG. 1 a;

FIG. 5b shows the insulation material of FIG. 5a with sides and endstrimmed to accommodate studs and top and bottom plates;

FIG. 5c shows the billet of FIG. 5b formed to define intermediate studaccommodations;

FIG. 5d shows the insulation member of FIG. 5c position for engagementwith a section of wall framing;

FIG. 5e shows the insulation member of FIG. 5c seated in the framing toform a modular wall sub-assembly;

FIG. 5f shows external sheathing positioned to mate with thesub-assembly of FIG. 5 e;

FIG. 5g show the sheathing of FIG. 5f mated to the sub-assembly;

FIG. 5h shows a next-adjacent insulated member seated in the wallframing of FIG. 5 d;

FIG. 5i shows external sheathing applied and fasteners installed tosecure the framing assembly of FIGS. 5d to 5 h;

FIG. 5j shows a pre-fabricated modular wall in final form;

FIG. 6 shows a cross-section of the insulation member of FIG. 5c withcross-hatching omitted to show pre-formed accommodation cuttingfeatures:

FIG. 7a is a front view of the pro-fabricated wall of FIG. 5j withservices access accommodation members removed;

FIG. 7b shows the front view of FIG. 7a with electrical and plumbingservice members added;

FIG. 7c shows an enlarged view of a detail of FIG. 7b ; and

FIG. 8 shows a width-wise abridged embodiment of the pre-fabricatedmodular wall assembly of FIG. 5j with some services installed.

DETAILED DESCRIPTION

The description that follows, and the embodiments described therein, areprovided by way of illustration of an example, or examples, ofparticular embodiments incorporating one or more of the principles,aspects and features of the present invention. These examples areprovided for the purposes of explanation, and not of limitation, ofthose principles, aspects and features of the invention. In thedescription, like parts are marked throughout the specification and thedrawings with the same respective reference numerals. The drawings maybe taken as being to scale, or generally proportionate, unless indicatedotherwise.

The scope of the invention herein is defined by the claims. Though theclaims are supported by the description, they are not limited to anyparticular example or embodiment, and any claim may encompass processesor apparatus other than the specific examples described below. Otherthan as indicated in the claims themselves, the claims are not limitedto apparatus or processes having all of the features of any oneapparatus or process described below, or to features common to multipleor all of the apparatus described below. It is possible that anapparatus, feature, or process described below is not an embodiment ofany claimed invention.

The terminology used in this specification is thought to be consistentwith the customary and ordinary meanings of those terms as they would beunderstood by a person of ordinary skill in the art in North America.The Applicants expressly exclude all interpretations that areinconsistent with this specification, and, in particular, expresslyexclude any interpretation of the claims or the language used in thisspecification such as may be made in the USPTO, or in any other PatentOffice, other than those interpretations for which express support canbe demonstrated in this specification or in objective evidence ofrecord, demonstrating how the terms are used and understood by personsof ordinary skill in the art, or by way of expert evidence of a personor persons of experience in the art.

This description discusses modular wall assemblies and elements of suchassemblies. In this discussion it may be helpful to make reference to aCartesian co-ordinate system. In the embodiments described, the x-axisor a-direction may be taken as being the height or heighth-wisedirection of the eventual assembly as assembled and installed in abuilding. In such installation the x-direction would most normally be avertical axis, although insulation members and modular panels accordingto the invention need not be vertical but could be horizontal orinclined. The y-direction may be taken as the horizontal directionrunning along the wall width-wise. In the description, the major facesof the modular wall panels tend to be planar surfaces extendingheighth-wise and width-wise in an x-y plane. The z-direction may betaken as the through-thickness direction of the wall panels and of theirpre-fabricated insulation member components. This co-ordinate systemassumes that the wall or wall module, or components thereof, is or are,viewed as finally installed. The terminology is nonetheless somewhatarbitrary and is understood whether the unit is installed in a verticalorientation, or is being processed in a factory in a horizontal or otherorientation. The commonly used engineering terms “proud”, “flush” and“shy” may be used herein to denote items that, respectively, protrudebeyond an adjacent element, are level with an adjacent element, or donot extend as far as an adjacent element, the terms correspondingconceptually to the conditions of “greater than”, “equal to” and “lessthan”.

Reference is made herein to insulated members. For the purposes of thisdiscussion a variety of commercially available thermal insulationmaterials could be used. Unless stated otherwise, the insulation membersare made of expanded rigid foam, such as EPS (expanded polystyrene),although other foams could be used, and, subject to the needs ofmanufacturing processes, a less rigid material might also be employed insome instances.

Reference is made herein to framing that is assembled on standardcenters or standard pitch spacing. The most common standard pitchspacings in North America are 12″, 16″, 19½″ and 24″ between centerlinesof next-adjacent spaced apart studs. Although any such spacing may beused, in the embodiments shown and described herein a pitch spacing of24″ may be assumed. Other countries may have different standarddimensions. In the components and assemblies herein there may be axes ofsymmetry, and, unless otherwise noted, it may be understood that adescription of one feature also provides a description of a symmetricalfeatures, other than for being of opposite hand.

Reference is made herein to studs. In the context of framing, a stud isa member that extends vertically between a base or bottom of floor plateand a top plate, and that is most typically loaded in verticalcompression. Studs may typically be made of construction grade softwoodlumber, and less commonly of roll-formed steel sections. Studs may be ofvarious standard sizes, most commonly nominal 2×4, 2×6, 2×8, 2×12 and2×12. Where reference is made to an electrical box, or socket, it may beunderstood that such boxes or sockets or switches, or other fittingstend to be supplied in standard sizes. A box 4″ high×1⅝ inches wide×1½inches deep is common, as are boxes 4″ wide×4″ high×1½ inches deep.Although deeper and wider enclosures are available, box and socketdepths of 1½ inches or 2 inches are customary.

In this description provision is made for the accommodation of services.The term “services” is intended to be generic and is intended to includeelectrical fittings, including junction boxes, sockets, switches andconduit; and plumbing fittings, such as piping or drains, whethercopper, pvc, or such other material as may be appropriate. It may alsoinclude other fittings, whether for telephone, home alarm, othercommunications or entertainment wiring and so on.

Referring to FIGS. 1a-1e , there is an insulation member designatedgenerally as 20. It is generally rectangular in shape, having a lengthor height L₂₀ (indicated in the x-direction) and a width W₂₀ (indicatedin the y-direction) and a through-thickness (indicated in thez-direction. The through thickness, t₂₀, is much smaller than either theheight or the width. The height, L₂₀, may correspond generally to theheight of a one story wall of a building, such as a residentialbuilding, less the height for the floor plate and the top plate. I.e.,the outside height dimension of the insulation corresponds to the insideheight dimension between the floor plate and the top plate. For anominally eight foot high wall, that resulting height dimension might beabout 7 ft, 8⅝″, and for a nominally nine foot high wall, that resultantheight might be about 8 ft, 8⅝″, for example. The width may correspondto the inside width between two adjacent studs in a wood-framed wall.Inasmuch as 2×4 or 2×6 studs may be spaced on 12″, 16″, 19.2″ or 24″centers, and may be 1⅝″ wide, in one embodiment such a width W₂₀ may beabout 22⅜″. In other embodiments W₂₀ may correspond to the appropriatewidth for 12″ centers, 16″ centers, or 19.2″ centers, as may be. Throughthickness t₂₀ may correspond to the depth of the studs in they-direction, or may be somewhat less than the through thickness asdiscussed in respect of further embodiment hereinbelow.

Insulation member 20 has two major sides, being the outside face 22 andthe inside face 24, extending in parallel, spaced apart x-y planes anddefining what might be considered the front and back of the paneldefined by insulation member 20. In the embodiment shown, outside face22 and inside face 24 are both generally rectangular. Insulation member20 also has four edge faces, being the bottom edge face 26, a top edgeface 28, a first (or left-hand) side face 30 and a second (orright-hand) side face 32. In this embodiment, side faces 30 and 32 maybe placed in engagement with, or immediately adjacent to the studs oneither side in the eventual wall panel assembly. The fit may be a slightinterference fit, such that the fit is reasonably snug. In this context,side faces 30 and 32 define first and second respective interfaces ofthe body of insulation member 20 and the adjacent studs.

It may be that, on installation, it is desired that the resultant wallpanel, or wall panel module, may have services mounted therein, whetherthose services be electrical fittings, plumbing fittings, or otherwise.It may tend to be inconvenient to make accommodations for such fittingsafter-the-fact on the job-site. Insulation member has pre-fabricatedprovision for such accommodations. For example, insulation member 20 hasa lengthwise running pre-cut (or slot, or notch, or incision, however itmay be termed) 34 such as may be made with a hot wire at the factory,rather than on the job site. Pre-fabrication may provide opportunitiesfor ease, efficiency and repeatability of fabrication, consistency andaccuracy of standard dimensions such as may be difficult to achieveexpeditiously on the job site with, for example, a knife or saw.

When seen in the view of FIG. 1b , looking parallel to the x-axis,pre-cut 34 has a first leg 36 running inwardly from first side face 30,and a second leg 38 running from the inner end of leg 36 toward insideface 24. First leg 36 may extend normal or perpendicular to first sideface 30, and may extend generally parallel to inside face 24 for adistance L₃₆. Distance L₃₆ may, for example, correspond to the width ofa 1½ inch wide electrical box such as might be used for a light switchor an electrical plug wall outlet socket. Second leg 38 extends towardinside face 24, and may extend generally perpendicular to inside face 24in an x-z plane. It does not reach inside face 24, however, but ratherterminates short thereof by a gap distance. Thus insulation member 20has a first or main body portion, designated as 40, and a second portion42, the first and second portions being joined at a neck 44. The widthof neck 44, designated t₄₄, defines the gap distance between leg 38 andfirst side face 30. Insulation member 20 may be made of a substantiallyrigid eps (expanded polystrene) or xps (extruded polystyrene) foam. Assuch second portion 42 may be rotated about a vertical axis away fromfirst portion 40, the bending motion tending to snap neck 44 such thatportion 42 may come away as a strip of insulation, leaving an emptychannel running in the heighth-wise direction, that channel having awidth corresponding to first leg 36 and a depth t₅₀ corresponding tosecond leg 38 plus t₄₄. The location of various snap lines, at which oneor another frangible neck may be intended to snap, is indicated in thevarious drawing views as an intermittent dashed line, or lines. Thethickness of neck 44 may be less than inch, in some embodiments may beless than ⅛, and may in some embodiments be in the range of about 1/16inch to 3/32 inches. The channel so formed may be termed, or may define,a service fitting accommodation 50 (which second portion 42 had formerlyoccupied) now open and exposed such as may facilitate the installationof service fitting such as electrical or plumbing fittings therein.Access to accommodation 50 is from the front (i e., from the inside faceof the wall as assembled), rather than requiring the installer to feedthe fittings through a narrow, not necessarily easily accessible hole orbore in an end-wall. In the various pre-cuts shown, described anddiscussed herein, the resulting accommodation faces may tend to beplanar or substantially planar, and may be cut with sharp 90 degree,right-angled corners. This need not necessarily be so—the planes couldbe oblique rather than perpendicular, the sides could be formed oncurves whether of cylindrical or conical form, and the corners could beformed on corner radii, or be chamfered, rather than being cut square.However it may be convenient to use perpendicular cuts and squarecorners as shown.

In the event that no such fitting is to be installed, portion 42 may beleft in place, with the inside face of portion 42, designated as 46,remaining as a generally co-planar portion or extension of inside face24 more generally. In the event that the full heighth-wise extent ofaccommodation 50 is not required, an installer may either (a) snap outportion 42, cut it to length, e.g., with a knife, and then re-installthe shortened cut remainder in the otherwise un-occupied portion ofaccommodation 50, thereby retaining the insulation value; or,alternatively, (b) the installer may use a marker on portion 42 prior toremoval, and then cut along the mark, or marks, (presumably in they-direction, inward from side face 30), and then rotate or snap thedesired section (or sections) of portion 42 out, leaving exposed reliefsor rebates, or cavities, or chambers, as may be, to accommodatewhichever service fitting is to be installed. The channel ofaccommodation 50 has substantially constant width and depth, may besized for standard fittings, is easily accessible from the front (i.e.,inside) face of the panel, and can be accessed merely by snapping outthe blank, or filler member, otherwise defined by portion 42, or suchpart thereof as may be removed.

Similarly, a second incision, or slot, or pre-cut, 54 may be formedinwardly of second side face 32, with first and second pre-cut legs 56and 58, to give an accommodation 60 on the opposite inside margin ofinsulation member 20 from accommodation 50, such the service fittingsmay be mounted to the studs along either side of insulation member 20.There may then be a third portion 62 of insulation member 20 thatdefines the blank or tab or filler that resides in accommodation 60until such time as neck 52 is snapped and third portion 62 may beremoved to permit the installation of services fittings, in like mannerto that described above in respect of accommodation 50. Third portion 62may be taken as being the same as second portion 42, but of oppositehand.

In either case, the service fitting accommodation is located immediatelyadjacent to the stud (i.e., running alongside a stud engagementinterface of insulation member 20), which is the most probable locationfor a light switch, plug, junction box of plumbing fitting, given thatthose fitting are most often secured by nails or screws or cleats to thestud.

It may be that a services channel, or channels, or access accommodation,may be desired that run cross-wise to insulation member 20. To that end,insulation panel may have a third pre-cut 64 extending inwardly intofrom inside face 24. Pre-cut 64 may have a first leg 66 extending in ay-z plane perpendicular to inside face 24, a second leg 68, which mayextend from first leg 66 in an x-y plane generally parallel to insideface 24, and a third leg 70 which may extend from second leg 68 backtoward inside face 24, defining a fourth portion 72 connected to firstportion 40 at a neck 74. In generally similar manner to second portion42 and third portion 62, fourth portion 72 may be rotated about they-axis to snap neck 74, thereby revealing a cavity or chamber of lateralchannel, identified as services fitting accommodation 80. As withaccommodations 50 and 60, an installer need not remove all of fourthportion 72, but may remove such part thereof as may be appropriate, ormay reinstall a cut remainder thereof in such portion of accommodation80 as may not be occupied by services fittings.

Third pre-cut 64 may be at a height x₈₀ suitable for the installation ofwall switches, and may, in one embodiment, have a bottom edge 50 inchesfrom the floor, and may be six inches in vertical extent L₈₀ asinstalled (i.e., ranging from 50 to 56 inches above the floor). Inaddition, insulation panel 20 may have a fourth pre-cut, 84 havingcorresponding legs 66, 68 and 70, being generally the same as pre-cut64, but located closer to floor level, as at a bottom edge of 14 inchesabove floor level (ranging from 14 inches to 20 inches above floorlevel) such as to provide a lower laterally (i.e., width-wise) extendingservice fitting accommodation 86, and frangibly removable portion 88which may be termed a tab, blank, or filler, as may be.

With the embodiment of FIGS. 1a-1e in mind, the embodiment of FIGS.2a-2e adds a further feature or step of complexity. That is, rather thanhaving a total through-thickness t₂₀ that is less than or equal to thethrough thickness of the studs with which insulated member 20 may beintended to be used, insulated member 120 may have a greater overallthrough-thickness t₁₂₀. For example, it may be desired that there be alayer of insulation between the studs and the outside sheathing of thewall member or module, such as may reduce thermal bridging in thex-direction. In one embodiment, of course, insulated member 20 may beused, and then another insulated member, such as a nominally 1 in. or 2in. (or thicker, as may be) sheet, whether 2 ft×8 ft, or 32″×96″, or 4ft×8 ft., may be mounted to the outside face of the studs, whileinsulation members 20 are mounted between the studs, or, alternatively,insulation members 20 may be adhesively (or otherwise) mounted to anexterior backing sheet of insulation, whether of the same type ordifferent, by pre-fabrication at the factory.

Further still, where insulation member 20 is of a certain throughthickness, such as may be suitable for use with studs of throughthickness x, yet is supplied where the actual stud dimension is x+2inches or x+4 inches. In such instance, insulation member 20 may be usedas the inside layer, one or more layers of 1 inch or 2 inch thicknessand a width to seat between studs spaced on the applicable stud centerdistance may be used behind insulation member 20, and then an externalsheet of the desired thickness may be applied outside the studs. Such alaminate can be assembled on site, or, alternatively, may be assembledat the factory as a pre-fabricated assembly or module.

However, rather than building up a laminate of a plurality ofco-operating insulation members, insulated member 120 of FIGS. 2a-2e maybe pre-fabricated from a single monolith of material stock. The monolithhas an outside face 122 and an inside face 124, extending in parallel,spaced-apart x-y planes, as before. The bottom, top, first and secondside faces are designated as 126, 128, 130, and 132, respectively.Bottom face 126 has been trimmed, as with a hot wire, to create acavity, or space, or accommodation, 134, which conforms to a top plateof the wall assembly, and top face 128 has a corresponding floor plateaccommodation 136. Similarly accommodations 138, 140 are formed in firstand second side faces 130, 132 for accommodating spaced apart studs ofthe framing. The hollow, or cavity, or relief, or rebate, oraccommodation 138 or 140 so formed may be termed a stud interface, orstud interface fitting. Viewed alternately, once trimmed, insulationmember 120 is left with outside face top, bottom, first side edge andsecond side edge flanges, respectively 142, 144, 146, and 148, that forma peripherally extending shoulder, abutment, or stop, and that, asinstalled, seat outside and against the top plate, floor plate and studsrespectively. It may be that the width W₁₃₈ of accommodations 138 and140 are half the width of a stud (i.e., half of 1⅝ inches), such thatthe installation of two adjacent insulation members 120 will yieldrespective mating flange halves covering the stud between them.

The remaining features of insulated member 120 may be taken as being thesame as the features of insulated member 20 previously described,including the services panel accommodations and frangible tabs orblanks. As may be noted, the flanged face is thus the outside face 122,and the inside face is the face 124 from which or by which the serviceschannels or accommodations are accessible.

The shoulder 118 formed by the flanges 142-148 also defines a locatingdatum for insulated member 120 more generally, that datum being locatedin a parallel x-y plane spaced from and intermediate to the planes ofoutside face 122 and inside face 124. That is, whatever the overallthrough thickness t₁₂₀ of insulated member 120 may be, the inside faceof the flanges, namely shoulder 118, define a stop or abutment, orindex, that will locate against the outside face of the studs, top plateand floor plate. The flange thickness t₁₄₈ may be set by themanufacturer to correspond to an appropriate external insulationthickness between the studs and the external sheathing. Similarly, thethickness of the inserted portion, t₁₄₀, lying inwardly of the flangedatum may also be set by the manufacturer. The thickness, t₁₄₀ may bethe same as the stud width, or in some embodiments it may be less thanthe stud width so that the studs, on installation, may extend slightlyproud of inside face 124, such that when internal sheathing, such asgypsum board, is applied there may be a clearance space between thegypsum board and inside face 124. That clearance space, of which anexample is shown in FIG. 8, may be of sufficient depth in the thicknessdirection to accommodate, for example, electrical wiring.

In the embodiment of FIGS. 3a and 3b , there is an insulated member 150which is substantially similar to insulated member 120. However, it mayoccur that at the end of a wall module or wall portion, the last studmay be positioned not on the full center spacing, but rather so that themost distant face of the stud is on the spacing. That is, supposing thata module is 48″ wide and 96″ tall, and the studs are on nominal 12″,16″, 19.2″ or 24″ centers. At the edges of the sheet, the side-most studwill be half on the sheet, and half off the sheet. If the module is inthe middle of a longer wall, then the end stud is half covered by theinsulation flange of one module, and half covered by the insulationflange of the next adjacent module. If, however, that module is the endmodule of the wall, then the stud needs to be moved over half its widthsuch that the laterally outside face of the stud lies in a plane flushwith the edge of the 48″×96″ external sheathing sheet.

To address that possibility, insulation member 150 has a main bodyportion 152 which includes the various peripheral flange members,designated collectively as 154. Along the first and second side edges orside margins 156, 158 of main body portion 152 are incisions, or slots,or notches or pre-cuts 160, 162 that extend into insulation member 150from inside face 164. Pre-cuts 160 and 162 are the same but of oppositehand.

Pre-cut 160 has a first portion, or first leg, 170 that may extend in anx-z plane from inside face 164 to a level flush with the abutment face166 (i.e., the flange shoulder datum) of the top plate and floor plateportions 142, 144 of flange 154. First leg 170 may be inset laterallyfrom side face 168 a distance W₁₇₀ corresponding to half the width ofthe stud size with which insulation member 150 is to be used. Side face168 may itself be offset ½ of the width of the stud from the outsideedge of flange 154, that distance being indicated as W₁₆₈. Pre-cut 160also has a second portion or second leg 172 being a lateral leg, whichmay extend in a plane parallel to inside face 164. Second leg 172 may beinset from inside face 164 the same distance as is leg 36, namely too adistance corresponding to a standard service fitting depth relative tothe ultimate inside face of the drywall sheet that may be mounted to theinside face of the stud. In one embodiment that distance may be set tosuit the depth of a 1½ inch box, a 2 inch box, or a 2½ inch box, where a2.5 inch box depth will, of course, also accommodate shallower boxes orfittings. Second leg 172 may have a first part 174 that extends fromfirst leg 170 away from side face 168, and a second part 176 thatextends from first leg 170 toward side face 168, leaving an uncutfrangible neck 178. At the other end of second leg 172 is a third leg,180 which extends back therefrom toward inside face 164 leaving afrangible neck 182. At the innermost end of first leg 170 is a fourthleg 184 extending outwardly toward end side face 168, level withshoulder 166 but stopping short to leave a frangible neck 186.

When insulation member 150 is installed in a mid-wall position, and noservice fittings are to be installed, none of the removable tabs orblanks are removed. When insulation member 150 is an end panel, thefinger 188 defined between first leg 170 of pre-cut 160 and first sideface 168 is removed, making the accommodation lying forward of flange146 have sufficient width to accommodate the full thickness of the stud.When insulation member 150 is in a mid-wall position, and a servicefitting is to be placed next to, or to run vertically alongside of, thestud, then the distal tip portion 190 of finger 188 is removed bysnapping frangible neck 178, and leaving proximal portion 192 of finger188 in place. The inboard portion of the service fitting accommodationis then exposed by snapping frangible neck 182 and removing strip 194.Insulation member 150 may also have provision for lateral, orwidth-wise, service fitting accommodations 80 and 86 in the same manneras insulated members 20 and 120, as previously described.

In summary, in the embodiment of FIGS. 3a and 3b insulation member 150is pre-fabricated from a block of insulation that has been trimmed witha hot wire to define a set of accommodations for wall framing membersalong top, bottom, left and right margins. Main body 152 has two majorportions, those being the flanged portion 155 lying to the outside ofthe datum defined by shoulder 118, or 166 as may be, and the main “plug”of body 152, identified as 165. Plug 165 conforms to the generallyrectangular shape of, and seats within, the generally rectangularopenings or bays defined by the top and bottom plates and the variousspaced-apart studs of the framing, thereby filling, or substantiallyfilling, with insulation the otherwise empty cavity in the framing. Thelateral margins of plug 165 also have three parts or portions, thosebeing the removable, frangible portions defined by items 190, 192 and194. The laterally extending service fitting accommodation blanks (i.e.,72, 88) also define frangible, removable portions.

In the embodiment of FIGS. 4a and 4b , there is an insulation member 200that is pre-fabricated from a stock monolith having the width of atleast two pitches of a framed wall. The first and second outside margins202, 204 may be as described in the context of the lateral or outsidemargins of insulation member 150 of the embodiment of FIGS. 3a and 3b .Insulation member 200 also has a central relief, or rebate, or chase, orchannel, identified as stud accommodation or stud channel 210 which isof a width corresponding to the thickness of a stud, and of a depth t₂₁₀from inside face 206 to flange abutment face 208 (or 118 or 166, as maybe) that is equal to or greater than the stud width, as previouslydiscussed.

On left and right hand sides of stud channel 210 are service fittingaccommodation incisions 212, 214 each having a first leg 216 extendinginto the body of insulation member 200 from inside face 206, and asecond leg 218 extending from the inner end of leg 216 toward studchannel 210, leaving a frangible neck 220. As previously explained, whenservice fittings are to be installed, the tab or blank, or fillerportion 222 is removed by snapping neck 220, revealing first or second(L or R) service fitting accommodation 224 or 226 as may be. The lead-incorners of stud channel 210 may be radiused or chamfered, as at 228 toease installation. As with insulation members 150, 120 and 20,insulation member 200 may also have laterally or cross-wise extendingservice fitting accommodations 80 and 86 formed ready-to-be-opened infront face 206.

FIGS. 5a-5j show a progression of steps in the manufacture and assemblyof an insulated wall panel and module. Insulation member 240 may be madefrom a monolithic block of insulation 48″ wide (W₂₄₀)×96″ high (L₂₄₀),with a through-thickness (t₂₄₀) such as may suit the studs and otherassembly members with which it is to co-operate. In a first step ofmanufacture in FIG. 5b , cuts are made to trim out accommodations forthe top plate and floor plate as at 242, and for the outside studs, asat 244. In this sequence of operations, cuts and incisions may have beenmade with a hot wire. As shown in FIG. 5c , further incisions are made,as with a hot wire, for example, to form spaced-apart stud channels 246and 248, which, in the instance of a 48″ wide member may be spaced on16″ centers. As shown, insulation member 240 is suitable for matingengagement with the elements of a framed wall structure 250, be it ofwood-framed or roll-formed steel structural elements. As can be seen inFIG. 5d , framed wall structure 250 includes a top plate 252, a floorplate 254 and studs 256 that run perpendicular to, between and infastened connection with, top plate 252 and floor plate 254. It may benoted that while a single 2×6 may be used for the floor plate, it iscustomary for the top plate to be doubled. Thus the cut out 242 made forthe floor plate may be 1½″, the insulation plug for filling the cavitybetween the studs is 92⅝, and the cut-out 242 made for the top platedefines a flange width corresponding to the remainder of the 96″dimension of the monolith of the stock material, roughly 1⅞ inches.

In FIG. 5e insulation member 240 is seated in mating engagement withframed wall structure 250, with the datum shoulder of the peripheralflange members 154 in abutting relationship with the outside faces ofthe respective members of framed wall structure 250. A panel of exteriorsheeting 238 is then mated to outside face 258 of member 240 as in FIGS.5f and 5g . In FIG. 5h another insulation member 240 is seated in thenext adjacent series of bays of wall structure 250, in side-by-sidefashion, and another panel of external sheeting 238 is put in place.Fasteners 236, such as nails or screws, are then driven through sheeting238 and the outer portion of insulation of insulation member 240 intostuds 256. A finished pre-fabricated panel module 260 is shown in FIG. 5j.

FIG. 6 shows the cuts or incisions made in insulation member 240 priorto assembly such as to provide the various fingers, tabs and frangiblenecks to define two-position edge stud widths as at 262 in the mannerexplained in the context of FIGS. 3a and 3b ; and to defineinner-face-accessible service fitting accommodations 264, 266, 268, 270,272, and 274, all as previously described in the context of FIGS. 3a and3b (264 and 274) and of FIGS. 4a and 4b (266, 268, 270, and 272). Aswith insulation members 20, 120, 150, and 200, insulation member 240 mayalso have provision for laterally extending service fittingaccommodations 80 and 86 as previously described.

FIGS. 7a-7c show a progression of installation of service fittings infinished module 260. FIG. 7a shows module 260 with all tabs, blanks andfillers removed to expose vertical and lateral service accommodations(224, 226 vertical, adjacent to studs 256; 80, 86 upper and lowerlaterals running between adjacent stud pairs). Channels 224, 226 are ofa width to permit nails or other fasteners to be driven through thefloor plate or top plate for attaching them to other structure, such asa sub-floor and joists.

In FIG. 7b , electrical sockets have been installed as at 280, 282, andwiring 284 drawn to the sockets down from top plate 252. Plumbingfittings have also been installed, as indicated at 286, 288, 290 and292, with bores having been made through successive joists 256. FIG. 7bshows a larger detail of the fitting installation. Removable members arereinstalled, or remain in, the unused service fitting accommodations, asindicated at 294, 296.

FIG. 8 shows an enlarged detail of a cross-section of a fully assembledwall structure 300, laterally abbreviated, showing the relationship ofthe various items as installed. The outside wall sheeting 302 is at thebottom of the view. Sheeting 302 is mated to insulation member 304 whichmay be representative of any of insulation members 150, 200 or 240. Anend stud 306 is seated in, or mates with the side edge interface definedby end accommodation 308 of insulation member 304, from which a finger184 has previously been removed. The inner portion of the servicefitting accommodation filler strip 310 remains in place as no servicefitting is located next to end stud 306.

Inside end 312 of end stud 306 stands inwardly proud of inside face 314of insulation member 304, leaving an air gap 316 of thickness t₃₁₆between inside face 314 and the back of the inside finishing covermember, identified as gypsum board 318. In a bay to the right, anopposed or second side face or side edge interface 320 of insulationmember 304 is defined by the left wall of the vertical stiffeneraccommodation identified as stud channel 322. To the left of studchannel 322, the vertical service fitting accommodation 324 is unused,and remains occupied by the tab or filler or blank 326. The section inthis part of the illustration is taken at a height on wall structure 300corresponding to a lateral service fitting chase or channel oraccommodation 80. On the right hand side of intermediate stud 332 is aservice fitting enclosure, in this instance an electrical junction box334 such as may house a socket or switch, or both, the internal wallcover plate being indicated as 336. Box 334 seats in the vacated lateralaccommodation 330, across which wiring may extend to electrical outletenclosure box 340 which is mounted to the next adjacent intermediatestud 342, the vertical filler strip having been removed fromaccommodation 344. On the right hand side of intermediate stud 342 thefiller strip 346 remains in unused accommodation 348, as does fillerstrip 350 in accommodation 352. Here, since the next stud to the right,354, is a normal intermediate stud half overlapped on each side byinsulation member 304, and half-overlapped on the other side by nextadjacent insulation member 356 of the next wall module, fingers 84remain in place, and stud 354 seats against the right hand studinterface of insulation member 304. The various studs are secured in thestud engagement interfaces or seats or channels by mechanical fasteners,such as nails, driven through outside sheeting 302 and through thechannel back portion 360 of insulation member 304 of thicknesscorresponding to the outside face peripheral flange thickness. To theextent that the internal wall cladding, be it gypsum board or otherwise,may be ½ inch thick, or thicker, and the air gap is ⅜ to ½ inch, theservice fitting accommodation may be ¾″ deep or deeper to accommodate 1½inch deep fittings.

The methods of manufacture and assembly described above presume thepre-existence of the assembled framing members, into which thepre-fabricated insulation members are then placed into thepre-constructed framing. However, both eps and xps are quite stiff, andinsulation members such as insulation member 20, 120, 150, 200,insulation member 240 or insulation member 304 may be prefabricated, andmay then themselves function as jigs in or with which to build up theframing of the modules, whether on the job site, or, perhaps moreefficiently, in a factory in which many panels can be assembled.

Several embodiments have been described hereinabove. Further embodimentscan be made combining the features and aspects of those embodiments insuch combinations and permutations as may be appropriate, as may beunderstood without need for redundant explanation of further descriptionof all of those possible combinations and permutations.

What has been described above has been intended illustrative andnon-limiting and it will be understood by persons skilled in the artthat other variances and modifications may be made without departingfrom the scope of the disclosure as defined in the claims appendedhereto. Various embodiments of the invention have been described indetail. Since changes in and or additions to the above-described bestmode may be made without departing from the nature, spirit or scope ofthe invention, the invention is not to be limited to those details butonly by the appended claims.

1.-27. (canceled)
 28. An insulation member sized to co-operate withframing studs, said insulation member having a height direction, a widthdirection, and a through-thickness direction, said insulation memberbeing large in each of said height direction and said width directionthan in said through-thickness direction, and wherein: said insulationmember has a first surface and an opposed second surface, each of saidfirst surface and said second surface extending in the directions of theheight and width; said insulation member having a portion thereofconnected thereto by a frangible neck; said portion running along saidfirst surface; when said neck is unbroken, said portion being secured ina fixed position; when said neck is broken, said portion being removableto leave a chase running along said first surface of said insulationmember, an exposed side of said chase being open, whereby to permitservice fittings to be laid sideways into said chase.
 29. The insulationmember of claim 28 wherein said portion defines an insulation blank,and, when said neck is unbroken, said blank occupies said chase.
 30. Theinsulation member of claim 29 wherein, when said neck is unbroken, saidportion lies flush with said first surface.
 31. The insulation member ofclaim 29 wherein said portion runs along an edge of said first surface.32. The insulation member of claim 29 wherein said portion runswidth-wise across said first surface.
 33. The insulation member of claim29 wherein said portion is a first said portion, and said insulationmember includes a second portion running along said first surface, saidsecond portion also being connected to said insulation member by afrangible neck.
 34. The insulation member of claim 33 wherein said firstportion runs parallel to said second portion along said first surface.35. The insulation member of claim 33 wherein said first portion runslength-wise along said first surface, and said second portion runswidth-wise along said surface.
 36. The insulation member of claim 29wherein said insulation member defines a plug for insertion betweenframing studs, and said second surface is of greater extent than saidfirst surface, said second surface defining a head larger than saidplug.
 37. The insulation member of claim 36 wherein said plug has athrough-thickness depth smaller than the framing studs, whereby, wheninstalled, said first surface of said insulated member lies shy of saidframing studs.
 38. The insulation member of claim 36 wherein saidinsulation member has an edge portion running in the height directiontherealong, and said edge portion includes a member connected thereto bya frangible neck, and, when said neck is broken said member of said edgeportion is removable to leave at least a portion of a studaccommodation.
 39. The insulation member of claim 29 wherein saidinsulation member includes a stud accommodation channel formed thereinrunning in the height direction, said channel having a widthcorresponding to a stud width, and extending a majority of the waythrough the through-thickness of said insulation member.
 40. Aninsulation member sized to co-operate with framing studs, saidinsulation member having a height direction, a width direction, and athrough-thickness direction, said insulation member being large in eachof said height direction and said width direction than in saidthrough-thickness direction, and wherein: said insulation member has afirst surface and an opposed second surface, each of said first surfaceand said second surface extending in the directions of the height andwidth; said insulation member having a portion thereof connected theretoby a frangible neck, said portion running in the height direction; whensaid neck is unbroken, said portion being secured in a fixed position;when said neck is broken, said portion being removable to leave a studaccommodation running along said first surface of said insulationmember, an exposed side of said stud accommodation being open.
 41. Theinsulation member of claim 40 wherein said portion runs along an edge ofsaid insulation member.
 42. The insulation member of claim 40 whereinsaid insulation member has a stud channel formed amidst said firstsurface, and said portion runs along an edge of said insulation memberdistant therefrom.
 43. The insulation member of claim 40 wherein saidinsulation member has a further frangible portion that, when snapped,leaves a chase running along said first surface of said insulatedmember.
 44. The insulation member of claim 43 wherein said chase runsalongside a stud accommodation of said insulation member.
 45. Theinsulation member of claim 43 wherein said chase runs width-wise acrosssaid first surface.
 46. An insulation member sized to co-operate withframing studs, said insulation member having a height direction, a widthdirection, and a through-thickness direction, said insulation memberbeing large in each of said height direction and said width directionthan in said through-thickness direction, and wherein: said insulationmember has a first surface and an opposed second surface, each of saidfirst surface and said second surface extending in the directions of theheight and width, and being separated from each other in saidthrough-thickness direction; said insulation member having at least onestud accommodation formed along an edge running in the height direction;said insulation member having a main body portion and a first portionconnected to said main body portion by a frangible neck; said firstportion running along said first surface; when said neck is unbroken,said first portion being secured in a fixed position relative to saidmain body; when said neck is broken, said first portion being removableto leave a chase running along said first surface of said insulationmember, an exposed side of said chase being open, whereby to permitservice fittings to be laid sideways into said chase.
 47. The insulationmember of claim 46 wherein: said insulation member having a secondportion thereof connected to said main body by a frangible neck, saidsecond portion running in the height direction; when said neck isunbroken, said second portion being secured in a fixed position; whensaid neck is broken, said second portion being removable to leave a studaccommodation running along said first surface of said insulationmember, an exposed side of said stud accommodation being open.